Xpost and xbeam

ABSTRACT

A modular frame system includes a structural member which can take the form of a vertical post or a horizontal beam. The member has a central, generally rectangular tubular body. The tubular body has four sides, two of which are connected by a substantially flat corner part. The member also has four fins extending from the tubular body in different directions for increased rigidity and stability. The fins also support floor, roof or wall panels. Holes are fabricated in the fins such that the member may be stacked on or attached to other similar structural members to create frameworks for buildings.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to structural members in the form of posts and beams and more particularly to an extruded structural aluminum shape, which after minor fabrication, can act as both a vertical column and/or a horizontal ledger beam to create a modular structure.

2. Brief Summary of the Invention

In accordance with one aspect of the present invention, a structural member is provided including a generally rectangular tubular body having four sides. Two of the sides are connected by a substantially flat corner part. The member also includes fins extending from the body.

The fins are integral with the body sides. Each of the fins extends beyond the body by a substantially equal distance. The fins extend in substantially orthogonal directions.

The body has a first set of two sides which intersect to form a corner. The two sides in the first set of sides are elongated to form the fins. Each of those two sides is substantially equal in length. Each is elongated in opposite directions to form two of the fins. Each of the fins extends beyond the body by a substantially equal distance. Each of fins is substantially equal in length.

The body has a second set of sides which are joined by the corner part. Each of those sides is substantially equal in length.

The member is formed of aluminum. The body will be hollow or filled.

The member may form a vertical post or a horizontal beam.

In accordance with another aspect of the present invention, a modular structural frame system is provided including a structural member. The member includes a generally rectangular tubular body having four sides. Two of the sides are connected by a substantially flat corner part. The member also has fins extending from the body.

The system includes two of the members and means for connecting the two members. The connecting means connects the two members in line with each other or at substantially right angles with each other. The right angle connecting means further includes a brace extending between the two members.

The member has a plurality of holes. The holes are spaced apart by an equal distance.

Preferably, the member has first and second parallel sets of equally spaced holes. The first and second hole sets are spaced apart by the same distance as the distance between adjacent holes in the first and second sets.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF DRAWINGS

To these and to such other objects that may hereinafter appears, the present invention relates to a structural member in the form of a post or beam made of aluminum for use in a modular building structure as described in detail in the following specification and recited in the annexed claims, taken together with the accompanying drawings, in which like numerals refer to like parts and in which:

FIG. 1A is an elevation view of the end of the post or beam of the present invention;

FIG. 1B is a perspective view of the post or beam of the present invention;

FIG. 1C is a cross-sectional view of a heavy duty embodiment of the post or beam of the present invention;

FIG. 1D is a cross-sectional view of a light duty embodiment of the post or beam of the present invention;

FIG. 2A is an elevation view from the top of four different length fabricated posts of the present invention;

FIG. 2B is an elevation view from the side of three different length fabricated beams of the present invention;

FIG. 2C is an elevation/section view of a typical contiguous framework formed of fabricated posts and beams of the present invention with horizontal member connections;

FIG. 3A is an elevation view of the top of an extruded aluminum member prior to fabrication into a vertical post of the present invention;

FIG. 3B is an elevation view of the top of the extruded aluminum member of FIG. 3A after fabrication into a vertical post of the present invention;

FIG. 3C is an elevation view of the top of an extruded aluminum member prior to fabrication into a horizontal beam of the present invention;

FIG. 3D is an elevation view of the top of an extruded aluminum member prior to fabrication into a horizontal beam of the present invention;

FIG. 3E is a plan view of the top of an extruded aluminum member after fabrication into a horizontal beam of the present invention;

FIG. 4A is a perspective view of a beam of the present invention prior to fabrication;

FIG. 4B is a perspective view of a column of the present invention prior to fabrication;

FIG. 4C is an exploded perspective view of a fabricated beam and a fabricated column of the present invention prior to being connected;

FIG. 4D is a perspective view of a fabricated beam and a fabricated column of the present invention after being connected;

FIG. 5A is a plan view of a structure formed from fabricated beams and fabricated columns of the present invention showing the corner connections;

FIG. 5B is an enlarged elevation view of a typical corner connection of the structure of FIG. 5A;

FIG. 6 is a perspective view of a box-like structure formed of fabricated beams and fabricated columns of the present invention;

FIG. 7A is a perspective view of a contiguous framework formed of fabricated beams and fabricated columns of the present invention;

FIG. 7B is a section/elevation view of a structure formed fabricated beams and fabricated columns of the present invention situated on a grade slab;

FIG. 7C is a section/elevation view of a structure formed fabricated beams and fabricated columns of the present invention with a raised floor;

FIG. 8A is a perspective view of a post section with a stacking connection of the present invention, including a cross-sectional view of standard solid rectangle part of stacking pin, an aluminum pipe as stacking pin and a plan view of the stacking pin spacer;

FIG. 8B is an elevation view of a two frame structure formed of fabricated beams and columns of the present invention showing the use of leveling jacks;

FIG. 8C elevation view of a multi frame structure formed of fabricated beams and columns of the present invention situated on a sloped grade; and

FIG. 8D is a perspective view of a framework formed of fabricated beams and columns of the present invention as it could be used to create a building.

DETAILED DESCRIPTION OF THE INVENTION

As illustrated in the drawings, the present invention relates to an extruded aluminum structural member with a unique shape, which after minor fabrication, can act both as a vertical column and/or a horizontal ledger beam to create a modular structure.

As seen in FIGS. 1A-1D, the member incorporates a central bearing tube body 10 and multiple integral attachment fins 12 a-12 d. This is a structural aluminum extrusion. This shape can be utilized to create a structural frame for a modular housing structure or other rectangular or square shaped, multi-columned structure such as shown in FIGS. 6, 7A-7C and 8A-8D.

The hollow tubular body 10 is extruded from structural (6061-T6 or equal) aluminum, with four projecting integral ‘fins’ or legs 12 a-12 d extending in different directions from tube 10. These fins are of equal thickness and dimension to one another and protrude from the hollow center column 10. Column or tube 10 has a generally square cross-sectional shape with a flat, elongated corner part 11.

FIG. 1A is an end view of the post structure showing the column or tube 10 and the outwardly extending fins or legs 12 a, 12 b, 12 c and 12 d. FIG. 1B shows the post before fabrication, in perspective view. FIG. 1C shows a heavy duty version of the post after fabrication in which column 10 is filled at 14. In this embodiment, fins 12 a-12 d are 10 mM thick and are provided with holes 16 for attachment to other members. FIG. 1D shows a light duty version of the post after fabrication. In this embodiment, column 10 remains hollow and the walls of the body and the fins are 6.35 mM thick. The fins are fabricated with holes 16 for attachment to other members.

FIG. 2A shows the structural member as it would appear fabricated into vertical posts in four different standard lengths of 2 m, 3 m, 4 m and 5 m. However, it is not required that the member be cut in any particular length. FIG. 2B shows the structural member as it would appear fabricated into horizontal beams in three different lengths. FIG. 2C shows a typical contiguous framework formed of the fabricated posts and beams, with horizontal member connections. The connections are illustrated in greater detail in FIGS. 4C, 4D, 5A and 5B.

FIG. 3A shows a vertical post prior to fabrication for attachment. FIG. 3B shows the vertical post after being fabricated with drilled or punched holes for attachment to other members. The holes are aligned in two spaced columns Preferably, the holes are equal distances apart, both horizontally and vertically. FIG. 3C shows a horizontal beam prior to fabrication for attachment. FIG. 3D is an elevation view of the horizontal beam after fabrication in which holes 16 have been drilled and the corners 18 at the opposite ends of fin 12 d have been removed. FIG. 3E is a plan view of the fabricated horizontal beam in which the fin corners 22 have been removed to allow the beam to bypass the fin on a post and attach to the post. The removed fin corners are a similar equal distance apart at each end, top and bottom.

FIG. 4A is a perspective view of a horizontal beam prior to fabrication. FIG. 4B is a perspective view of a vertical post column prior to fabrication. FIG. 4C shows the beam and column after fabrication for attachment and how the members are attached. It should be noted that in this figure the corners 22 of fin 12 d have been removed to allow the horizontal beam to be attached to the vertical post. FIG. 4D is a perspective view of the attached beam and post.

FIG. 5A is a plan view showing typical corner connections in greater detail, including braces 24 which extend between members attached at a right angle. The ends of the braces are attached to the members by bolts passing through holes 16 and meet each of the members at a 45 degree angle. Also shown in this figure are the notched or cut-away ends 22 of the vertical post fins such that they lie flush to remaining connection plates on the horizontal beams FIG. 5B shows an elevation view of a typical corner connection in detail.

As illustrated in FIGS. 3A-3E, 4A-4C, 5A and 5B, for attachment purposes, a series of common sized holes 16 (typically maximum hole diameter is double the thickness of the fin or 13 mm- 9/16″), a fixed dimension apart, are drilled or punched through each fin at a common interval and common level. Each ‘fin’ is structural and can be used to fasten to a vertical or horizontal member by aligning the holes on the member with the holes on a vertical or horizontal member to which it is to be attached. The member can then be bolted or pinned as the attachment to the vertical or horizontal member. Other methods of attachment such as self-tapping screws or fabricated pins (structurally calculated for size and quality) are acceptable.

FIG. 6 is a perspective view of a typical box frame configuration formed of the post and beam members of the present invention. It includes a lower ledger framework 26 formed of four horizontal beams, and upper ledger framework formed of four horizontal beams 28. The lower ledger framework and upper ledger framework are connected by four vertical posts.

In the configuration of FIG. 6, the vertical posts or columns are conjoined with horizontal beam members to create a lower four-sided ledger structure. Additional horizontal beam members would be similarly attached with bolts to create a roof or upper ledger structure. Bracing of the system would require the addition of diagonal bracing 24 (shown in FIG. 5A) made of light round tubing, angle, square or rectangular steel or aluminum tubing or other fabricated structural members of various length and/or structural capacity which are then bolted or pinned through the holes in the horizontal or vertical members fins, to create a braced, completed structure. The bracing components typically are mounted at a 45° angle relative to the members being braced.

FIG. 7A is a perspective view of a contiguous framework formed of the post and beam members of the present invention. The floor of the framework is formed of horizontal beams supported by leveling jacks 30 with spaced cross members for supporting floor panels 32. Various types of floor panels may be used, including those formed of steel corrugated with a plywood deck, a steel deck supporting light concrete or insulated structural plywood composite panels. The fins of the horizontal floor beams provide an integral lintel for supporting siding panels 32 which may be pre-fabricated panelized wallboard, or made of local masonry or of stucco. The roof ledger framework is formed of horizontal beans and is supported by vertical jam/wall ledge posts. The horizontal roof beams are connected by spaced cross members designed to support roof panels 34. Roof panels 34 are provided with a membrane to permit water collection. The tops of the vertical posts extend above the plane of the roof ledger framework and are adapted to be connected to the ledgers of an adjacent dwelling unit.

FIG. 7B shows that a typical four-column framework formed of the structural members of the present invention. The framework is positioned on a concrete slab. Concrete anchors, a base plate and slab anchorage pins connected to the bottom of the vertical posts are provided for that purpose. FIG. 7C shows that a framework formed of the members of the present invention may alternatively rest on a solid surface. Leveling jacks 30 resting on a concrete or wood sill may be used. In that case, the horizontal beans which form the floor ledger are connected to the vertical posts at a point spaced from the bottom of the posts to obtain a raised floor.

Diagonal braces 24 are also shown in this figure. The diagonal or lateral bracing components 24 are used. Braces 24 are composed of lightweight steel or aluminum tubing and would be installed to additionally brace and create increased rigidity of the entire conjoined structure. Use of standard angles, round, square or rectangular tubing is acceptable. Bracing components 24 are cut to size and holes are placed near the ends to allow for bolt or similar attachment to vertical and horizontal members.

The fins of the vertical members allow the attachment to the fins of a horizontal member with bolts or pins. As seen in FIGS. 3E and 4C, this requires the removal of a small corner part 22 of one horizontal fin so as to allow the other fins to bypass and thereby align and fit flush to the fin of the vertical member.

By utilizing two bolts or two pins, per attachment, per member, it forces the members to stay square and plumb to one another. The bolts or pins would be sized to sustain a given load. Commonly, the bolt would be a minimum Grade 5 bolt, twice the thickness of the fin, with washers and a nut. Equivalent sizes in metric could be used. Also a fabricated structural pin could be utilized. The holes in the fin would be sized to fit the bolt or pin to be utilized. The holes in the fin could be oblong or slots, but predominately round. FIGS. 4D, 5A and 5B depict typical simple connections of horizontal to vertical members.

As seen in FIG. 7A, a single ledger level condition is also possible if column bases are anchored to a solid base such as a concrete pad for stability. Lateral load stability is achieved by the conjoined and braced structure which is able to withstand substantial horizontal and vertical loads (i.e. wind, etc.) in any direction. The fins, either horizontal or vertical, can be used to support corrugated steel floor deck or roof deck or other wall, floor or roof panels especially fabricated to fit, interlock or lay on the ledger fin to provide adequate load capacity at a given span.

FIG. 8A shows that a post stacking connection pin 36 is used to connect posts together in line with each other. Stacking pin 36 is bolted to the ends of the posts to be connected, as illustrated. Two embodiments of stacking pin 36 are shown. One embodiment 36 a has a standard solid rectangular cross-sectional shape. The other embodiment 36 b of the stacking pin is a solid aluminum tube or pipe. The top portion of the figure is a plan view showing the details of how the stacking pin is bolted to the post. The fin tube spacer with attached (tack welded) heavy aluminum angle or rectangle serves as an internal stacking pin.

FIG. 8B shows an elevation view of a two frame structure formed of fabricated beams and columns of the present invention. The figure shows the use of leveling jacks 30 anchored to base pads, resting on concrete footing. It also shows braces 24.

FIG. 8C is elevation view of a multi frame structure formed of fabricated beams and columns of the present invention. The structure may be situated on a sloped grade or on rocky ground. In that case, the vertical posts are supported vertically on vertical adjusting threaded leveling ‘screw-jacks’ 30 with appropriate sized bearing plates or on formed footings which can be used for leveling the entire system. The screw-jacks allow for leveling the system on uneven terrain.

FIG. 8C also shows that the members of the present invention may be used to form conjoined multi-columned structures. In order to create an even larger and more rigid system, each rectangular or square ‘box’ structure could be conjoined with other boxes of similar components to create a continuous series of framed ‘rooms’ or other structures.

Also shown in this figure is the use of the frames stacked on each other to form structures with more than one floor. In the figure, a second floor is situated over the first floor form a duplex structure.

FIG. 8C also shows that columns formed of the members of the present invention can be stacked to create multi-tiered structures. The columns are stacked utilizing the stacking pin or pipe shown in FIG. 8A that slides into each column and is pinned or bolted to each column Columns stacked atop one another would create a higher or multi-leveled structure.

FIG. 8D is a perspective view of a framework formed of fabricated beams and columns of the present invention as used to create a building. The building has a raised floor 38 formed of steel roof decking screwed down to the horizontal beams and covered with light concrete panels. An entrance door 40 is adjacent a raised platform 42 which includes stairs 44. Side panels 46 have window openings 48 and support a sleeping cot 50. Roof 52 is formed of steel roof panels screwed to the fins of the horizontal beams and covered with light weight concrete decking with a drain which may connect to a cistern. An awning 58 is provided. The building is situated adjacent a hen house or shed 60.

A single ledger level condition is also possible if column bases are anchored to a solid base such as a concrete pad for stability.

Structures formed of members of the present invention should have some sort of anchorage or base support. The completed structure should be anchored to: (1) its foundation/slab; (2) the earth via earth anchors (or similar devices) or (3) available counterweights, which can safely counteract any wind forces applied to the surface of the shelter or structure. Local codes establish the wind loads/forces which apply.

While only a limited number of preferred embodiments of the present invention have been disclosed for purposes of illustration, it is obvious that many modifications and variations could be made thereto. It is intended to cover all of those modifications and variations which fall within the scope of the present invention, as defined by the following claims. 

1. A structural member comprising a generally rectangular tubular body having four sides, two of said sides being connected by a substantially flat corner part, and fins extending from said body.
 2. The member of claim 1 wherein said body is hollow.
 3. The member of claim 1 wherein said body is filled.
 4. The member of claim 1 wherein said fins are integral with said body.
 5. The member of claim 1 wherein each of said fins extends beyond said body by a substantially equal distance.
 6. The member of claim 1 said body has a first set of two sides which intersect to form a corner and wherein said two sides in said first set of sides are elongated to form said fins.
 7. The member of claim 6 wherein each of said two sides in said first set of sides are substantially equal in length.
 8. The member of claim 6 wherein said two sides in said first set of sides are each elongated in opposite directions to form two of said fins.
 9. The member of claim 8 wherein each of said two of said fins are substantially equal in length.
 10. The member of claim 8 wherein each of said two of said fins extend beyond said body by a substantially equal distance.
 11. The member of claim 1 wherein said body has a second set of sides which are joined by said corner part.
 12. The member of claim 11 wherein each of said sides of said second set of sides is substantially equal in length.
 13. The member of claim 1 wherein said fins extend in substantially orthogonal directions.
 14. The member of claim 1 wherein said member is formed of aluminum.
 15. The member of claim 1 wherein said member forms a vertical post.
 16. The member of claim 1 wherein said member forms a horizontal beam.
 17. A modular structural frame system comprising a structural member, said member comprising a generally tubular rectangular body having four sides, two of said sides are connected by a substantially flat corner part, and fins extending from said body.
 18. The system of claim 17 wherein said body has a two other sides which intersect to form a corner and wherein said two other sides are elongated to form said fins.
 19. The system of claim 17 wherein said fins extend in substantially orthogonal directions.
 20. The system of claim 17 further comprising two of said members and further comprising means for connecting said two members.
 21. The system of claim 20 wherein said connecting means connects said two of said members in line with each other.
 22. The system of claim 20 wherein said connecting means connects said two of said members at substantially right angles with each other.
 23. The system of claim 22 wherein said connecting means further comprises a brace extending between said two members.
 24. The system of claim 17 wherein said member has a plurality of holes and wherein said holes are spaced apart by an equal distance. 